Apparatus for removing heat from injection devices and method of assembling same

ABSTRACT

A method of assembling an injection device for use in a reactor injector feed assembly includes extending the injection device at least partially into a cavity. The injection device includes a plurality of substantially concentric conduits coupled to a modular tip that includes a plurality of cooling channels and a plurality of substantially annular nozzles defined therein. The method also includes coupling at least one coolant distribution device in flow communication with the plurality of cooling channels to facilitate removing heat from an outer surface of the injection device.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/854,636, filed Aug. 11, 2010, which is hereby incorporated byreference in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates generally to injection systems, such asthose used in gasification systems, and more particularly, to methodsand apparatus to facilitate removing heat from modular tip injectiondevices used with gasification reactors.

Most known IGCC plants include a gasification system that is integratedwith at least one power-producing turbine system. For example, at leastsome known gasification systems convert a mixture of fuel, air oroxygen, steam, and/or CO₂ into a synthetic gas, or “syngas.” The syngasis channeled to the combustor of a gas turbine engine, which powers anelectrical generator that supplies electrical power to a power grid.Exhaust from at least some known gas turbine engines is supplied to aheat recovery steam generator (HRSG) that generates steam for driving asteam turbine. Power generated by the steam turbine also drives anelectrical generator that provides electrical power to the power grid.

At least some known gasification systems include an injection systemthat supplies a gasification reactor with process fluids to facilitateat least one exothermic reaction. The injection system may include atleast one injection device that is partially exposed to such exothermicreactions and the associated high temperatures. Such high temperaturesmay reduce the useful life span of some of the components within theinjection devices.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, a method of assembling an injection device for use in areactor injector feed assembly is provided. The method includesextending the injection device at least partially into a cavity. Theinjection device includes a plurality of substantially concentricconduits coupled to a modular tip that includes a plurality of coolingchannels and a plurality of substantially annular nozzles definedtherein. The method also includes coupling at least one coolantdistribution device in flow communication with the plurality of coolingchannels to facilitate removing heat from an outer surface of theinjection device.

In another aspect, an injection device for use in a reactor injectorfeed assembly is provided. The injection device includes a plurality ofsubstantially concentric conduits coupled to a modular tip that includesa plurality of substantially annular nozzles. The injection device alsoincludes an outer surface extending into a cavity such that the outersurface is exposed to a source of heat within the cavity. The injectiondevice further includes a plurality of cooling channels defined withinthe injection device. Each of the cooling channels is at least one ofradially and axially inward of the outer surface. The injection devicealso includes at least one coolant distribution device coupled in flowcommunication with the plurality of cooling channels to facilitateremoving heat from at least a portion of the outer surface.

In yet another aspect, a gasification facility is provided. Thegasification facility includes at least one carbonaceous reactant sourceand at least one oxygenated fluid reactant source. The gasificationfacility also includes at least one gasification reactor including atleast one injection device coupled in flow communication with the atleast one carbonaceous reactant source and the at least one oxygenatedfluid reactant source. The at least one injection device includes aplurality of substantially concentric conduits coupled to a modular tipthat includes a plurality of substantially annular nozzles. The at leastone injection device also includes an outer surface extending into theat least one gasification reactor such that the outer surface is exposedto a source of heat within the at least one gasification reactor. The atleast one injection device further includes a plurality of coolingchannels defined within the injection device. Each of the coolingchannels is at least one of radially and axially inward of the outersurface. The at least one injection device also includes at least onecoolant distribution device coupled in flow communication with theplurality of cooling channels to facilitate removing heat from at leasta portion of the outer surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an exemplary gasification facility;

FIG. 2 is a schematic cross-sectional view of a gasification reactorthat may be used for synthetic gas generation, such as may be used withthe gasification facility shown in FIG. 1;

FIG. 3 is a schematic perspective view of an exemplary injector feedassembly that may be used with the gasification reactor shown in FIG. 2;

FIG. 4 is an exploded view of the exemplary injector feed assembly shownin FIG. 3;

FIG. 5 is a schematic perspective view of a portion of the exemplaryinjector feed assembly shown in FIG. 3;

FIG. 6 is a schematic cross-sectional view of a tip portion of aninjection device that may be used with the injector feed assembly ofFIG. 5 taken along area 6;

FIG. 7 is another schematic cross-sectional view of the exemplary tipportion shown in FIG. 6;

FIG. 8 is a schematic cross-sectional view of an exemplary seal assemblyshown in FIGS. 6 and 7;

FIG. 9 is a schematic rear view of an exemplary adaptor portion that maybe used with the tip portion shown in FIG. 5;

FIG. 10 is a schematic cross-sectional view of the tip portion shown inFIG. 6;

FIG. 11 is a schematic cross-sectional view of a plurality of coolingchannels within the tip portion shown in FIG. 10;

FIG. 12 is a front view of an alternative tip portion of an injectiondevice that may be used with the injector feed assembly shown in FIG. 5;and

FIG. 13 is a flow chart of an exemplary method of assembling theinjection device shown in FIGS. 2, 3, 10, and 12.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a schematic diagram of an exemplary facility that uses aninjection system, specifically, a gasification facility, and morespecifically, an exemplary integrated gasification combined-cycle (IGCC)power generation plant 100. Alternatively, the method and apparatus toproduce synthetic gas as described herein is used with any facility inany suitable configuration that that enables such method and apparatusincluding, but not limited to, any combustion facilities, chemicalprocessing facilities, and food processing facilities.

In the exemplary embodiment, IGCC plant 100 includes a gas turbineengine 110. A turbine 114 is rotatably coupled to a first electricalgenerator 118 via a first rotor 120. Turbine 114 is coupled in flowcommunication with at least one fuel source and at least one air source(both described in more detail below) and is configured to receive thefuel and air from the fuel source and the air source (neither shown inFIG. 1), respectively. Turbine 114 mixes air and fuel, produces hotcombustion gases (not shown), and converts the heat energy within thegases to rotational energy. The rotational energy is transmitted togenerator 118 via rotor 120, wherein generator 118 converts therotational energy to electrical energy (not shown) for transmission toat least one load, including, but not limited to, an electrical powergrid (not shown).

IGCC plant 100 also includes a steam turbine engine 130. In theexemplary embodiment, engine 130 includes a steam turbine 132 rotatablycoupled to a second electrical generator 134 via a second rotor 136.

IGCC plant 100 further includes a steam generation system 140. In theexemplary embodiment, system 140 includes at least one heat recoverysteam generator (HRSG) 142 that receives exhaust gases (not shown) fromturbine 114 via an exhaust gas conduit 148 that supplies heat usedwithin HRSG 142 to produce one or more streams of steam from at leastone boiler feedwater source that includes, but is not limited to, atleast one heated boiler feedwater stream (not shown). HRSG 142 also iscoupled in flow communication with at least one heat transfer apparatus144 via at least one steam conduit 146. Apparatus 144 is also coupled inflow communication with at least one heated boiler feedwater conduit(not shown), wherein apparatus 144 receives heated boiler feedwater (notshown) from the same or a separate boiler feedwater source (not shown).HRSG 142 receives steam (not shown) from apparatus 144 via conduit 146,wherein HRSG 142 facilitates addition of heat energy to the steam. HRSG142 is coupled in flow communication with turbine 132 via a steamconduit 150. In the exemplary embodiment, the cooled combustion gasesare exhausted from HRSG 142 to the atmosphere via stack gas conduit 152.Alternatively, at least a portion of the excess combustion gases fromHRSG 142 are channeled for use elsewhere in IGCC plant 100.

Conduit 150 is configured to channel steam (not shown) from HRSG 142 toturbine 132. Turbine 132 is configured to receive the steam from HRSG142 and convert the thermal energy in the steam to rotational energy.The rotational energy is transmitted to generator 134 via rotor 136,wherein generator 134 is configured to facilitate converting therotational energy to electrical energy (not shown) for transmission toat least one load, including, but not limited to, the electrical powergrid. The steam is condensed and returned as boiler feedwater via acondensate conduit (not shown). Alternatively, at least a portion of thesteam from HRSG 142, steam turbine 132 and/or heat transfer apparatus144 is channeled for use elsewhere in IGCC plant 100.

IGCC plant 100 also includes a gasification system 200. In the exemplaryembodiment, system 200 includes at least one air separation unit 202coupled in flow communication with an air source via an air conduit 204.The air sources include, but are not limited to, dedicated aircompressors (not shown) and a compressor (not shown) typicallyassociated with gas turbine engine 110. Unit 202 is configured toseparate air into one or more streams of oxygen (O₂), nitrogen (N₂) andother component streams (neither shown). The other component streams maybe released via a vent (not shown) or collected in a storage unit (notshown). In the exemplary embodiment, at least a portion of N₂ ischanneled to gas turbine 114 via a N₂ conduit to facilitate combustion.

System 200 includes a gasification reactor 208 that is coupled in flowcommunication with unit 202 and is configured to receive the O₂channeled from unit 202 via an O₂ conduit 210. System 200 also includesa material grinding and slurrying unit 211. Unit 211 is coupled in flowcommunication with a carbonaceous material source and a water source(neither shown) via a carbonaceous material supply conduit 212 and awater supply conduit 213, respectively. In the exemplary embodiment, thecarbonaceous material is petroleum coke, or pet coke. Moreover, in theexemplary embodiment, Unit 211 is configured to mix the pet coke andwater to form a pet coke slurry stream (not shown) that is channeled toreactor 208 via a pet coke slurry conduit 214. Alternatively, anymaterial that includes carbonaceous solids is used that facilitatesoperation of IGCC plant 100 as described herein. Also, alternatively,non-slurry fuels that include solid, liquid and gaseous fuel substancesare used, including mixtures of fuels and other materials, such as butnot limited to, fuel and slag additives.

Reactor 208 is configured to receive the material slurry stream and anO₂ stream via conduits 214 and 210, respectively. Reactor 208 is alsoconfigured to facilitate production of a hot, raw synthetic gas (syngas)stream (not shown). Moreover, reactor 208 is also configured to producehot slag and char (both not shown) as a by-product of the syngasproduction.

Reactor 208 is coupled in flow communication with heat transferapparatus 144 via a hot syngas conduit 218. Apparatus 144 is configuredto receive the hot, raw syngas stream and transfer at least a portion ofthe heat to HRSG 142 via conduit 146. Subsequently, apparatus 144produces a cooled, raw syngas stream (not shown) that is channeled to ascrubber and low temperature gas cooling (LTGC) unit 221 via a syngasconduit 219. Unit 221 is configured to remove the portion of slag andchar entrained within the raw syngas stream (sometimes referred to as“fines”) and facilitate removal of the fines via a fines conduit 222.The fines are sent to a waste collection system (not shown) for ultimatedisposal and/or recirculated back into gasification reactor 208 to takeadvantage of unused carbon content within the fines. Unit 221 is alsoconfigured to further cool the raw syngas stream.

Apparatus 144 also facilitates removal of slag and char from the hot,raw syngas stream. Specifically, a slag and char handling unit 215 iscoupled in flow communication with apparatus 144 via a hot slag conduit216. Unit 215 is configured to quench the balance of the char and slag,simultaneously breaking up the slag into small pieces wherein a slag andchar removal stream (not shown) is produced and channeled throughconduit 217. In a manner similar to the fines discussed above, the slagand char are channeled to a waste collection subsystem (not shown) forultimate disposal and/or recirculated back into gasification reactor 208to take advantage of unused carbon within the slag and char.

System 200 further includes an acid gas removal subsystem 230 that iscoupled in flow communication with unit 221 and is configured to receivethe cooled raw syngas stream via a raw syngas conduit 220. Subsystem 230is also configured to facilitate removal of at least a portion of acidcomponents (not shown) from the raw syngas stream as discussed furtherbelow. Such acid gas components include, but are not limited to, H₂S andCO₂. Subsystem 230 is further configured to facilitate separation of atleast some of the acid gas components into components that include, butare not limited to, H₂S and CO₂. In the exemplary embodiment, CO₂ is notrecycled and/or sequestered. Alternatively, subsystem 230 is coupled inflow communication with reactor 208 via at least one CO₂ conduit (notshown) wherein a stream of CO₂ (not shown) is channeled to predeterminedportions of reactor 208. The removal of such CO₂ and H₂₅ via subsystem230 facilitates producing a clean syngas stream (not shown) that ischanneled to gas turbine 114 via a clean syngas conduit 228.

In operation, air separation unit 202 receives air via conduit 204. Theair is separated into O₂, N₂ and other components. The other componentsare vented or collected, wherein at least a portion of N₂ is channeledto turbine 114 via a conduit 206 and at least a portion of O₂ ischanneled to gasification reactor 208 via conduit 210. Remainingportions of N₂ and O₂ may be channeled as a plurality of streams toother portions of IGCC 100 as needed, including, but not limited to,storage. Also, in operation, material grinding and slurrying unit 211receives pet coke and water via conduits 212 and 213, respectively,forms a pet coke slurry stream and channels the pet coke slurry streamto reactor 208 via conduit 214.

Reactor 208 receives the O₂ via conduit 210, pet coke via conduit 214.Reactor 208 facilitates production of a hot raw syngas stream that ischanneled to apparatus 144 via conduit 218. Some of the slag by-productthat is formed in reactor 208 is removed via slag handling unit 215 andconduits 216 and 217. Apparatus 144 facilitates cooling the hot rawsyngas stream to produce a cooled raw syngas stream that is channeled toscrubber and LTGC unit 221 via conduit 219 and the syngas is cooledfurther. Particulate matter, including some of the slag and char (in theform of fines), is removed from the syngas via conduit 222. The cool rawsyngas stream is channeled to acid gas removal subsystem 230 whereinacid gas components are selectively removed such that a clean syngasstream is formed and channeled to gas turbine 114 via conduit 228.

Further, in operation, turbine 114 receives N₂ and clean syngas viaconduits 206 and 228, respectively. Turbine 114 compresses air from atleast one air source (not shown) that turbine 114 subsequently mixes andcombusts with the syngas fuel, producing hot combustion gases. Turbine114 channels the hot combustion gases to induce rotation of turbine 114which subsequently rotates first generator 118 via rotor 120. At least aportion of the exhaust gases are channeled to HRSG 142 from turbine 114via an exhaust gas conduit 148 to facilitate generating steam.

At least a portion of the heat removed from the hot syngas via heattransfer apparatus 144 is channeled to HRSG 142 as steam via conduit146. HRSG 142 receives the steam from apparatus 144, together with oneor more streams of boiler feed water, as well as the exhaust gases fromturbine 114. Heat is transferred from the exhaust gases to the one ormore streams of boiler feedwater as well as the steam from apparatus144, thereby producing one or more subsequent streams of steam as wellas increasing the heat energy contained in the steam from apparatus 144.In the exemplary embodiment, at least one of the streams of steamgenerated as described above is heated to superheated conditions.Alternatively, one or more of the aforementioned streams of steam aremixed together to form one or more mixed streams that may be heated tosuperheated conditions. Alternatively, high temperature saturated steamis formed. At least a portion of the superheated steam is channeled tosteam turbine 132 via conduit 150 and induces a rotation of turbine 132.Turbine 132 rotates second generator 134 via second rotor 136. Aremaining portion of the steam is channeled for use elsewhere withinIGCC plant 100.

FIG. 2 is a schematic cross-sectional view of gasification reactor 208that may be used for synthetic gas generation, such as may be used withIGCC power generation plant 100. Reactor 208 includes at least oneinjection device 300 that is coupled in flow communication with agasification cavity 302. In the exemplary embodiment, device 300 is anannular triplet gasifier injector nozzle as described herein, therebyincluding three annular passages (described further below).Alternatively, device 300 is any suitable injector nozzle that includes,but is not limited to, configurations with four or more annularpassages. Further, alternatively, device 300 is any suitable injectornozzle that includes, but is not limited to, three or more concentricpassages, wherein each passage is coupled in flow communication with theannular passages described above in any suitable configuration thatfacilitates operation of injection device 300 as described herein.

Cavity 302 is at least partially defined by a substantially cylindricalreactor wall 304 and a head end cover 306. In the exemplary embodiment,gasification reactor 208 is substantially cylindrical. Alternatively,reactor 208 includes any configuration that facilitates operation ofreactor 208 as described herein. Also, in the exemplary embodiment,device 300 has a substantially vertical orientation (described furtherbelow) wherein device 300 penetrates the top of reactor 208 and pointssubstantially downward. Alternatively, device 300 has any orientationincluding, but not limited to, substantially horizontal orientations.

In the exemplary embodiment, wall 304 includes at least one ceramicrefractory material that includes, but is not limited to, heat temperedbricks. Alternatively, wall 304 is fluid-cooled, wherein the coolingfluids include, but are not limited to water and/or steam. Cover 306 issealingly coupled to at least a portion of a head end portion 308 ofreactor 208. Cavity 302 is also partially defined by a tail end cover(not shown) that is sealingly coupled to at least a portion of wall 304,wherein the tail end cover is positioned on a tail end portion 310 thatis in opposition to portion 308. Alternatively, cover 306, head endportion 308, the tail end cover and tail end portion 310 are oriented inany suitable position relative to wall 304, including any orientationthat facilitates operation of reactor 208 as described herein.Furthermore, wall 304 may be of any configuration that facilitatesoperation of reactor 208 as described herein. Moreover, alternatively,reactor 208 has any suitable configuration that facilitates operation ofIGCC 100 as described herein.

Injector device 300 includes a tip portion 312 that is inserted throughan aperture 314 defined in head end cover 306 and sealingly coupled tohead end cover 306 using a fastening method that includes, but is notlimited to, retention hardware (not shown). Reactor 208 is configuredsuch that an axial centerline 316 of injector device 300 is collinearwith a longitudinal centerline 318 of gasification cavity 302. Tipportion 312 is configured to form a plurality of recirculation zoneswithin cavity 302. Specifically, tip portion 312 is configured to form afirst recirculation zone 320 a first distance D₁ from tip portion 312within gasification cavity 302. Recirculation zone 320 has a shape thatis substantially toroidal and the shape is one of substantiallyspatially continuous or partially segmented. Moreover, recirculationzone 320 is positioned close to and, with respect to centerline 318,substantially centered about centerline 318. Also, specifically, tipportion 312 is configured to form a second recirculation zone 322 asecond distance D₂ from tip portion 312 within gasification cavity 302.Recirculation zone 322 has a shape that is substantially toroidal andthe shape is one of substantially spatially continuous or partiallysegmented. Moreover, recirculation zone 322 is positioned with respectcenterline 318, that is, substantially centered about centerline 318,and in close proximity to wall 304. First recirculation zone 320 isproximately centered within second recirculation zone 322.

Alternative embodiments of reactor 208 may include a plurality ofinjection devices 300, wherein each device 300 has a centerline 316,such that each associated centerline 316 is co-linear with a predefinedaxial orientation similar to centerline 318. Each of such plurality ofdevices 300 may have either a vertical, i.e., directly upward and/ordirectly downward, and/or a horizontal orientation, including anyorientation between purely vertical and purely horizontal orientations,that facilitates operation of reactor 208 as described herein.Furthermore, such alternative embodiments of reactor 208 may include aplurality of devices 300, wherein all of devices 300 have asubstantially similar orientation. Moreover, such alternativeembodiments of reactor 208 may include a plurality of devices 300,wherein a first number of such injectors 300 have a differingorientation than a second number of such devices 300.

Still further alternative embodiments of reactor 208 may include aplurality of devices 300 wherein devices 300 are distributed across oneor more surfaces of reactor 208, each device 300 with a differingorientation. Moreover, injectors 300 making up at least a portion ofplurality of injectors 300 may each be placed in a dedicated cavity (notshown) that is a part of, or otherwise joined with, reactor 208, therebyfacilitating separate formation or development of multiple recirculationzones from each such injector 300.

FIG. 3 is a schematic perspective view of an exemplary injector feedassembly 319 that may be used with gasification reactor 208 (shown inFIG. 2). Injection device axial centerline 316 and gasification cavitylongitudinal centerline 318 are illustrated for perspective. In theexemplary embodiment, injector feed assembly 319 is a bayonet assembly.Specifically, assembly 319 includes a first bayonet section, that is, aninner oxygen (O₂) supply section 321 that is coupled in flowcommunication to an O₂ source similar to O₂ conduit 210 (shown in FIG.1). Assembly 319 also includes a second bayonet section, that is, amiddle slurry section 323 that is coupled in flow communication to aslurry source similar to material slurry conduit 214 (shown in FIG. 1).Assembly 319 further includes a third bayonet section, that is, an outerO₂ supply section 324 that is coupled in flow communication to an O₂source similar to O₂ conduit 210. At least a portion of section 324extends about at least a portion of section 323, at least a portion ofsection 323 extends about at least a portion of section 321, and, atleast a portion of section 324 extends about at least a portion ofsection 321. Moreover, sections 321, 323, and 324 terminate where theyjoin tip 312 in flow communication. Therefore, sections 321, 323 and 324define a plurality of substantially concentric passages or channels, or,specifically, an inner O₂ channel, a middle slurry channel, and an outerO₂ channel (neither shown in FIG. 3) within assembly 319.

Assembly 319 also includes an O₂ bypass line 325 that establishes atleast some flow communication between bayonet sections 324 and 321 suchthat a predetermined O₂ mass flow rate distribution is facilitated basedat least partially upon cumulative predetermined O₂ pressure drops thatoccur as O₂ is channeled through bayonet sections 321 and 324, O₂ bypassline 325, and subsequent components as O₂ is discharged from assembly319. Therefore, maintaining predetermined ratios of an outer O₂ massflow rate and an inner O₂ mass flow rate (neither shown) is facilitated.Bypass line 325 facilitates installation and operation of assembly 319in retrofits of gasification reactor 208. Alternatively, methods thatinclude, but are not limited to flow orifices and manually-operated andautomated throttle valves are used in conjunction with, or in lieu of,bypass line 325.

Assembly 319 further includes a cooling fluid inlet manifold 326 and acooling fluid outlet manifold 327 coupled in flow communication with tipportion 312 of injection device 300 via a plurality of cooling fluidcoils 328. Manifolds 326 and 327 and coils 328 facilitate channeling acooling fluid to remove heat from tip portion 312 (discussed in moredetail below). Assembly 319 also includes a mounting flange 329 that isremovably and sealingly coupled to head end cover 306 using a fasteningmethod that includes, but is not limited to, retention hardware (notshown). Alternatively, assembly 319 includes at least one cooling jacketwith cooling fluid supply and return means integral with at least aportion of outer O₂ supply section 324 between mounting flange 329 andtip portion 312 that facilitates channeling of cooling fluid to removeheat from tip portion 312. Also, alternatively, assembly 319 has anynumber of coolant connections and/or coolant flow means that facilitateoperation of injection device 300 as described herein.

FIG. 4 is an exploded view of the exemplary injector feed assembly 319.In the exemplary embodiment, inner oxygen supply section 321 ispositioned at least partially within slurry supply section 323, which isat least partially positioned within outer oxygen supply section 324.Assembly 319 has a “bayonet” design, wherein sections 321, 323, and 324hereon are also referred to as bayonets and/or bayonet sections 321,323, and 324. Bayonet section 321 includes an end 343, bayonet section323 includes an end 342, and bayonet section 321 includes an end 341.

FIG. 5 is a schematic perspective view of a portion of injector feedassembly 319, including area 6. FIG. 6 is a schematic cross-sectionalview of tip portion 312 of injector feed assembly 319 taken along area 6(shown in FIG. 5). FIG. 7 is another schematic cross-sectional view oftip portion 312 that is oriented 90° about axial centerline 316 from theperspective shown in FIG. 6. Tip portion 312 controls the distributionof flow of reactant supply fluids between injector feed assembly 319 andgasification cavity 302 (shown in FIG. 2). FIG. 7 shows a support pin498.

Moreover, as illustrated in the exemplary embodiment, adapter portion332 includes three substantially annular adapters: an outer gaseousoxygen (GOX) bayonet adapter 336, a slurry bayonet adapter 338, and aninner GOX bayonet adapter 340. Bayonet adapters 336, 338, and 340 arecoupled in flow communication with bayonet sections 324, 323 and 321(all shown in FIG. 3), respectively. More specifically, outer GOXbayonet adapter 336 is coupled to an end 341 of bayonet section 324(both shown in FIG. 4). Slurry bayonet adapter 338 is coupled to an end342 of bayonet section 323 (both shown in FIG. 4). Inner GOX bayonetadapter 340 is coupled to an end 343 of bayonet section 321 (both shownin FIG. 4).

In the exemplary embodiment, adapter portion 332 may be fabricated as aplurality of extensions of bayonet sections 321, 323, and 324 ofassembly 319, rather than as a component or components of tip portion312. That is, in the exemplary embodiment, outer GOX bayonet adapter336, slurry bayonet adapter 338, and inner GOX bayonet adapter 340 areseparate pieces that are individually coupled to bayonet sections 321,323, and 324, respectively, during assembly of injector feed assembly319. Alternatively, at least two of bayonet adapters 336, 338, and 340are coupled together to form a single piece. That is, alternatively, tipportion 312 includes an integrated, unitarily-formed bayonet adapterportion 332 and a modular tip 334, wherein adaptor portion 332 iscoupled to bayonet sections 321, 323, and 324 of assembly 319.

In the exemplary embodiment, slurry bayonet adapter 338 and inner GOXbayonet adapter 340 partially define a reactant, or slurry, channel 344.Slurry channel 344 is in flow communication with a middle coal slurrychannel (not shown) defined and extending within assembly 319 (shown inFIG. 3). In the exemplary embodiment, slurry bayonet adapter 338 andouter GOX bayonet adapter 336 partially define an outer reactantchannel, that is, an outer GOX channel 345, and inner GOX bayonetadaptor 340 partially defines an inner reactant channel, that is, aninner GOX channel 346. Inner GOX channel 346 and outer GOX channel 345are coupled in flow communication with an inner and an outer oxygenchannel (neither shown) defined and extending within assembly 319.Alternatively, either of channels 345 and 346 are oriented to channelany process fluid that facilitates operation of gasification reactor 208including, but not limited to, steam, nitrogen and carbon dioxide, andchannels 345 and 346 are coupled in flow communication with theappropriate fluid sources.

Adapter portion 332 is coupled to injector feed assembly 319 via knownmethods such as, but not limited to, welding, brazing, and/or retentionhardware (not shown).

To form the first recirculation zone 320 and the second recirculationzone 322 (both shown in FIG. 2), tip portion 312 includes both divergingand converging nozzles. More specifically, a plurality of nozzles isformed within modular tip 334 including an inner GOX nozzle 348, aslurry nozzle 350, and an outer GOX nozzle 352. Inner GOX nozzle 348 andslurry nozzle 350 direct respective process fluids away from injectoraxial centerline 316, and are referred to as diverging nozzles. OuterGOX nozzle 352 directs a respective process fluid toward injector axialcenterline 316, and is therefore referred to as a converging nozzle.Alternatively, outer GOX nozzle 352 is either a divergent nozzle or aparallel nozzle with respect to injector axial centerline 316.

Injection device 300, that includes injector feed assembly 319 with tipportion 312 having both diverging and converging nozzles includingnozzles 348, 350, and 352, facilitates mixing of the reactant streams,that is, the slurry and GOX streams (neither shown) at predeterminedangles with predetermined momentums. Nozzles 348, 350, and 352 alsofacilitate improving an efficiency of chemical reactions between theslurry and oxygen.

Orienting and configuring nozzles 348, 350, and 352 as discussed hereinhas beneficial results that include, but are not limited to,facilitating vaporization of the reactants. Specifically, formingrecirculation zones 320 and 322 facilitates increasing a residence timeof the slurry and GOX such that exothermic reactions between thecarbonaceous material and GOX occur more effectively. Moreover, anadditional benefit of forming such recirculation zones 320 and 322 inthe vicinity of head end portion 308 (shown in FIG. 2) facilitatesincreasing heat release in that vicinity, and therefore facilitatesvaporization of water in the slurry stream. However, due to localizedexothermic reactions and associated heat releases, portions of injectiondevice 300, that is, at least one outer surface of injection device 300,is exposed to hot syngas (not shown) including, but not limited to, aradially inner external surface 354 (also shown in FIG. 4) of tipportion 312 and a radially outer external surface 356 of tip portion312. Such high temperature exposures are discussed further below.

In general, initial assembly of, as well as post-commissioning fieldservice and maintenance disassembly and reassembly of known injectorassemblies are each complicated by including both diverging andconverging nozzles within such injector assemblies. For example, in mostcases, it is difficult to remove a known bayonet having a diverging tipthat at least partially forms a diverging nozzle from a next largerknown bayonet if the larger bayonet has a converging tip with aconverging nozzle that is similar to, or smaller in size than thediverging tip, since such converging tip may interfere with axialremoval of such diverging tip. Therefore, partial disassembly of tipportion 312 by disassembly of divergent nozzles 348 and 350 fromconvergent nozzle 352 is especially difficult. One method of disassemblywhere such interferences occur between the nozzles in the injectorincludes removing the injector (that is, injector 300 as describedherein) from the reactor cavity (that is, cavity 302 as described hereinand shown in FIG. 2), and cutting off the tips of the known bayonets.

However, in the exemplary embodiment, modular tip 334 simplifiesassembly, disassembly, and field service of injection device 300 whilefacilitating the use of a combination of diverging and convergingnozzles 348, 350, and 352. This simplification is achieved since theconverging and diverging nozzles 348, 350, and 352 are formed withinmodular tip 334, which is releasably coupled to adapter portion 332.Bayonet adapters 336, 338, and 340 are sized such that each adapter andrespective bayonet can be removed from the next larger adapter andrespective bayonet when modular tip 334 is not coupled to adapterportion 332.

In the exemplary embodiment, modular tip 334 is fabricated as a singlecomponent from a plurality of individual components that are joinedtogether by known coupling methods including, for example, brazing orwelding. Alternatively, one-piece modular tip 334 may be formed bymethods that include direct metal laser sintering. One-piece modular tip334 is coupled in flow communication with adapter portion 332. Modulartip 334 may be fabricated as one-piece to achieve a desired degree ofnozzle precision and also to ease field assembly and disassembly. Also,in the exemplary embodiment, modular tip 334 is removably coupled toadapter portion 332 via known coupling methods that include, but are notlimited to, retention hardware 353 (discussed further below).Alternatively, modular tip 334 is removably coupled to adapter portion332 via any known coupling methods that enable operation of modular tip334 as described herein. Retention hardware 353 and external surface 354are proximate to each other.

Further, in the exemplary embodiment, tip portion 312, which includesmodular tip 334 and adaptor portion 332 removably coupled together viaretention hardware 353 rather than welded together, also includes aplurality of seals that are used to maintain separation between slurrychannel 344, outer GOX channel 345, inner GOX channel 346, cooling watermanifold 326, cooling water manifold 327, and a flow of hot syngas (notshown) within cavity 302 that is external to injector feed assembly 319.More specifically, in the exemplary embodiment, a seal assembly 357maintains a separation between outer GOX channel 345 and the syngascontacting external surface 354. Moreover, a seal assembly 358 maintainsa separation between outer GOX channel 345 and slurry channel 344. Inaddition, a seal assembly 359 maintains a separation between slurrychannel 344 and inner GOX channel 346. Furthermore, a seal assembly 360facilitates maintaining a separation between cooling fluid inletmanifold 326, outer GOX channel 345, and hot syngas that contactsexternal surface 354. Still further, a seal assembly 361 facilitatesmaintaining separation between cooling fluid outlet manifold 327, outerGOX channel 345, and hot syngas that contacts external surface 354. Sealassemblies 357, 358, 359, 360, and 361 are manufactured from anymaterials in any configuration that enables operation of modular tip 334as described herein including, without limitation, metallic seals,o-rings, and e-seals, singular or redundant seals, and any combinationthereof.

Each of seal assemblies 357, 358, 359, 360, and 361 facilitatespreventing unintended mixing of the process fluids and coolants used inthe gasification process while utilizing an injector tip that includesmultiple components that are not connected together by welding orbrazing. Specifically, during assembly of tip portion 312 that includescoupling adapter portion 332 to modular tip 334, the shapes of themating surfaces of adaptor portions 332, 338 and 340 and tip 322, sealassemblies 360 and 361 facilitate alignment and attainment ofpredetermined gaps between portions 332, 338 and 340 and tip 334 toattain a predetermined gap (not shown) therebetween to furtherfacilitate secure coupling of portions 332, 338 and 340 with tip 334.This is at least partially due to seal assemblies 360 and 361 havingsmaller diameters than seal assemblies 357, 358, and 359, thereby sealassemblies 360 and 361 are more likely to attain a full circumferentialcrush thereon. Also, specifically, seal assemblies 357, 358, and 359facilitate providing a greater tolerance range within tip 334 tofacilitate a greater tolerance for variances due to fabrication andassembly, and shifting and movement of components therein.Alternatively, one of seals 357, 358 or 359 may be used to facilitatethe alignment and attainment of predetermined gaps between portions 332,338 and 340 with tip 334. Further alternatively, any means known tothose familiar with the art may be used to facilitate alignment andattainment of predetermined gaps between portions 332, 338, and 340 withtip 334.

Moreover, in the exemplary embodiment, tip portion 312 includes one ofcoolant supply conduit 370 and one coolant return conduit 374, whereinsuch conduits 370 and 374 include, but are not limited to, plenums,chambers, and channels (neither shown). In the exemplary embodiment,conduit 370 and conduit 374 are positioned on opposite sides ofcenterlines 316 and 318. Alternatively, a plurality of conduits 370 and374 are used, wherein the plurality of conduits 370 are positionedadjacent to each other on one side of centerlines 316 and 318, whileeach of conduits 374 are positioned adjacent to each other on theopposite side of centerlines 316 and 318. Also, alternatively, conduits370 and 374 are positioned in an alternating manner about centerlines316 and 318. Further, alternatively, one or more bifurcated conduits maybe used in place of conduits 370 or 374, wherein one portion of eachsuch bifurcated conduit operates as a coolant return conduit. Moreover,alternatively, any configuration of conduits 370 and 374 may bepositioned in any manner about centerlines 316 and 318 that enableoperation of tip portion 312 as described herein.

FIG. 8 is a schematic cross-sectional view of an exemplary seal assembly359. In the exemplary embodiment, seal assemblies 357 and 358 aresubstantially similar. A mating end 380 of inner GOX nozzle 348 andinner GOX bayonet adapter 340 define a first longitudinal gap 382, aradial gap 384, and a second longitudinal gap 386, wherein gaps 382,384, and 386 are in flow communication with each other. Moreover, gaps382, 384, and 386 extend substantially radially within tip portion 312(shown in FIGS. 6 and 7). Mating end 380 and bayonet adapter 340 alsodefine a first seal gland 388 and a second seal gland 390, wherein bothglands 388 and 390 extend substantially radially within tip portion 312.In the exemplary embodiment, seal assembly 359 includes a plurality ofseals 392. More specifically, a first seal 394 is positioned withinfirst seal gland 388 and a second seal 396 is positioned within secondseal gland 390, wherein both seals 394 and 396 extend substantiallyradially within tip portion 312.

Also, in the exemplary embodiment, radial gap 384 is at least partiallytapered. Such tapering facilitates mating up and alignment of bayonetadapter 340 and nozzle 348. Second seal 396, sometimes referred to asthe main seal, facilitates manufacturing and assembly tolerances andvariations of longitudinal gaps 382 and 386. First seal 382, cooperateswith mating end 380, bayonet adapter 340, and radial gap 384 tofacilitate alignment and mating of bayonet adapter 340 and nozzle 348,decreasing a potential for metal-to-metal contact thereof, facilitatesdampening movement of bayonet adapter 340 and nozzle 348 as a result ofmechanical vibration, and facilitates a reduction in foreign debriscollection including, without limitation, fuel particles, within gaps382, 384, and 386 that could potentially interfere with the operationof, or decrease an expected life of, main seal 396. Moreover, while inthe exemplary embodiment, seal assembly 359 is configured and orientedas described above, alternatively, any configuration and orientation ofseal assembly 359 that enables operation of seal assembly 359 and tipportion 312 as described herein is used.

FIG. 9 is a schematic rear view of adaptor portion 332. In the exemplaryembodiment, modular tip 334 is removably coupled to adapter portion 332via retention hardware 353 using tools that include, but are not limitedto, a torque wrench 362. Retention hardware 353 extends through adaptorportion 322 into modular tip portion 334, wherein hardware 353 engagesboth portions 332 and 334. As retention hardware 353 is tightened duringassembly of tip portion 312 that includes coupling adapter portion 332to modular tip 334, the shapes of the mating surfaces of adaptorportions 332, 338 and 340 and tip 322, seal assemblies 360 and 361facilitate alignment and attainment of predetermined gaps (not shown)between portions 332, 338 and 340 with tip 334 to attain a predeterminedgap (not shown) therebetween to further facilitate secure coupling ofportions 332, 338 and 340 with tip 334. Also, specifically, sealassemblies 357, 358, and 359 facilitate providing a greater tolerancerange within tip 334 to facilitate a greater tolerance for variances dueto fabrication and assembly, and shifting and movement of componentstherein.

Therefore, in the exemplary embodiment, tip portion 312, includingadapter portion 332 that is removably coupled to modular tip 334 viaretention hardware 353, wherein modular tip 334 includes convergent anddivergent nozzles 348, 350, and 352, facilitates assembly, disassembly,and field service of injection device 300. Moreover, modular tip 334facilitates use of a fixed configuration therein regardless of thermalexpansion effects of bayonet sections 321, 323, and 324 that may haveany length and/or inherent manufacturing tolerances.

FIG. 10 is a schematic cross-sectional view of tip portion 312. InnerGOX adapter 340 (included within bayonet adapter portion 332) issubstantially aligned with an inner GOX tip 452 (included within modulartip 334), and adapter 340 and tip 452 form a slip fit upon coupling ofbayonet adapter portion 332 to modular tip 334. Also, seal assembly 359is positioned between inner GOX adapter 340 and inner GOX tip 452. Sealassembly 359 is at least partially crushed, or compressed to facilitatepreventing fluid from leaking between inner GOX channel 346 and slurrychannel 344 at the mating surfaces (not shown) between adapter 340 andtip 452.

Inner GOX tip 452 is positioned substantially concentrically within aslurry tip 454 that is also included within modular tip 334. Optionally,at least one spacer (not shown) facilitates maintaining a predeterminedspacing between inner GOX tip 452 and slurry tip 454, thereby at leastpartially defining slurry channel 344. Slurry adapter 338 (includedwithin bayonet adapter portion 332) is substantially aligned with slurrytip 454, and adapter 338 and tip 454 form a slip fit upon coupling ofbayonet adapter portion 332 and modular tip 334. Also, seal assembly 358is positioned between slurry adapter 338 and slurry tip 454. Sealassembly 358 is at least partially crushed, or compressed to facilitatepreventing fluid from leaking between slurry channel 344 and outer GOXchannel 345 at the mating surfaces (not shown) defined between slurryadapter 338 and slurry tip 454.

Injector body, or outer GOX adapter 336 is substantially aligned with aninjector body 470 of modular tip 334, and adapter 336 and body 470 forma slip fit upon coupling of bayonet adapter portion 332 and modular tip334. Outer GOX adapter 336 and injector body 470 at least partiallydefine outer GOX channel 345. Also, seal assembly 357 is positionedbetween outer GOX adapter 336 and injector body 470. Seal assembly 357is at least partially crushed, or compressed to facilitate preventingfluid from leaking between outer oxygen channel 345 and syngas atsurface 354 of outer GOX adapter 336 at the mating surfaces (not shown)defined between outer GOX adapter 336 and injector body 470.

Outer GOX adapter 336 and injector body 470 are releasably coupled, inthe exemplary embodiment, by a plurality of retention hardware 353(shown in FIGS. 7 and 9) that include threaded fasteners. Retentionhardware 353 not only couples adapter portion 332 to modular tip 334,but also induces a clamping, or compressing force for seal assemblies357, 358, 359, 360, and 361 as described above.

A GOX center body 490 is positioned within inner GOX tip 452. Slurry tip454 is inserted within injector body 470, and slurry tip 454, inner GOXtip 452, and GOX center body 490 are maintained in position by at leastone coolant spoke 492 and 494 and/or at least one support pin 498 (shownin FIG. 7). Furthermore, spokes 492 and 494 and/or support pin 498facilitate decreasing a potential for shifting of components withinmodular tip 334 due to thermal expansion and contraction andmanufacturing tolerances.

A radially outer cooling face plate 500 and a radially inner coolingface plate 502 may be positioned on exterior surfaces of injector body470 and GOX center body 490. The cooling face plates 500 and 502facilitate shielding tip portion 312 from heat damage.

Tip portion 312 includes a cooling fluid supply plenum 600 that iscoupled in flow communication cooling fluid supply manifold 326. Plenum600 is defined within injector body adaptor 336 and an adjoining opening(not shown) defined within injector body 470. In the exemplaryembodiment, plenum 600 is substantially cylindrical. Alternatively,plenum 600 has any configuration that facilitates operation of tipportion 312 as described here. Plenum 600 is coupled in flowcommunication with an axially inner circumferential cooling channel 602and an axially outer circumferential cooling channel 604. Channels 602and 604 circumferentially extend about tip portion 312 and facilitateforming an axially inner circumferential cooling surface 606 and anaxially outer circumferential cooling surface 608, respectively.Moreover, channels 602 and 604 are configured to channel a portion ofcoolant flow as illustrated by the associated arrows. Further, channels602 and 604 and surfaces 606 and 608 are sized to facilitate heatremoval from proximate portions of tip portion 312.

Tip portion 312 also includes a cooling fluid return plenum 610 that iscoupled in flow communication with cooling fluid return manifold 327 andchannels 602 and 604. Plenum 610 is defined within injector body adaptor336 and an adjoining opening (not shown) defined within injector body470. In the exemplary embodiment, plenum 610 is substantiallycylindrical. Alternatively, plenum 610 has any configuration thatfacilitates operation of tip portion 312 as described here. Plenum 610is configured to receive coolant flow from channels 602 and 604 (as wellas additional coolant flows that are discussed further below).

Tip portion 312 further includes a radially outer coolant supply plenum612 that is coupled in flow communication with plenum 600. Plenum 612 isdefined within injector body 470 and is configured to receive at least aportion of the fluid coolant flow as illustrated with the associatedarrows. Tip portion 312 also includes a plurality of cooling slots, orchannels 614 formed within radially outer cooling face 500 and radiallyinner cooling face 502. At least a portion of each of faces 500 and 502form a cooling surface. In the exemplary embodiment, channels 614 aresubstantially circumferential. Alternatively, channels 614 have anyconfiguration that facilitates operation of tip portion 312 as describedherein. Further, channels 614 and surfaces 606 and 608 are sized tofacilitate heat removal from proximate portions of tip portion 312.

Channels 614 include a plurality of radially outer cooling channels 616and at least one flow distribution device, that is, at least oneradially outer cooling channel inlet orifice plate 618 that are bothcoupled in flow communication with plenum 612. Plate 618 is configuredto control the distribution of cooling fluid through each of channels616.

Tip portion 312 further includes a radially outer coolant return plenum620 that is defined within injector body 470 and is configured toreceive at least a portion of the fluid coolant flow discharged fromchannels 616 via a plurality of radially outer cooling channel outlets622 as illustrated with the associated arrows.

Tip portion 312 also includes a radially inner coolant supply plenum 624that is defined within injector body 470 and is coupled in flowcommunication with plenum 600 via coolant supply spoke 494. Channels 614also include a plurality of radially inner cooling channels 626 and atleast one radially outer cooling channel inlet orifice plate 628 thatare coupled in flow communication with plenum 624. Plate 628 isconfigured to control the distribution of cooling fluid through each ofchannels 626. Plates 618 and 628 are also configured to preventinadvertent cross-installation during fabrication and/or assembly. Tipportion 312 further includes a radially inner coolant return plenum 630that is defined within injector body 470 and is configured to receive atleast a portion of the fluid coolant flow discharged from channels 626via a plurality of radially outer cooling channel outlets 632 asillustrated with the associated arrows. Plenum 610 is coupled in flowcommunication with plenum 630 via coolant return spoke 492. Tip portion312 also includes a flow separation wall 634 that is configured tofacilitate separation of coolant flows within spoke 494 and plenum 624from coolant flows within spoke 492 and plenum 630.

In the exemplary embodiment, the plurality of plenums, channels, spokes,orifice plates and wall 634 not only facilitate coolant flow throughouttip portion 312, they also facilitate structural support of tip portion312. Alternatively, tip portion 312 includes any structural supportfeatures that facilitate operation of tip portion 312 as described here.

FIG. 11 is a schematic cross-sectional view of a plurality of coolingchannels within the tip portion. In FIG. 11, radially outer cooling faceplate 500 and radially inner cooling face plate 502 (both shown in FIG.10) are shown removed from injector body 470 and GOX center body 490,respectively (both shown in FIG. 10). As described above, cooling faceplates 500 and 502 facilitate shielding tip portion 312 from heatdamage.

Radially outer cooling channel inlet orifice plate 618 is coupled inflow communication with radially outer coolant supply plenum 612.Orifice plate 618 includes a plurality of orifices 640 coupled in flowcommunication with radially outer cooling channels 616, wherein each oforifices 640 is sized to facilitate a predetermined coolant flow ratewithin cooling channels 616. Channels 616 are coupled in flowcommunication with radially outer cooling channel outlets 622 that are,in turn, coupled in flow communication with radially outer coolantreturn plenum 620.

Similarly, radially inner cooling channel inlet orifice plate 628 iscoupled in flow communication with radially inner coolant supply plenum624. Orifice plate 628 includes a plurality of orifices 642 coupled inflow communication with radially inner cooling channels 626, whereineach of orifices 642 is sized to facilitate a predetermined coolant flowrate within cooling channels 626. Channels 626 are coupled in flowcommunication with radially inner cooling channel outlets 632 that are,in turn, coupled in flow communication with radially inner coolantreturn plenum 630.

In the exemplary embodiment, channels 616 and 626 are grooves definedwithin plates 500 and 502, respectively, by associated channel walls644. Alternatively, channels 616 and 626 are formed in any manner thanenables operation of modular tip 312 as described herein. Also, in theexemplary embodiment, channels 616 and 626 are sized with a channelradial width W to facilitate use of thinner metal for plates 500 and502, thereby facilitating a reduction in stresses induced therein andextending a life cycle of tip portion 312. Further, in the exemplaryembodiment, a channel axial depth D (shown as extending into FIG. 11) issized to facilitate heat removal by channels 616 and 626. Moreover, inthe exemplary embodiment, channel radial width W and channel axial depthD are sized in conjunction with a channel radial length L and coolingwater flow to facilitate a predetermined rate of heat removal for eachindividual channel 616 and 626. For example, but not limited to, coolingwater flow is sized to accommodated varying channel radials length L,and axial depth D is sized differently for each of channels 616 suchthat cooling fluid velocities within each of channels 616 issubstantially similar.

Also, in the exemplary embodiment, orifice plates 618 and 628 arepositioned at the inlets to channels 616 and 626, respectively.Alternatively, orifice plates are positioned at the outlets of channels616 and 626. Also, alternatively, orifice plates are positioned at bothinlets and outlets of channels 616 and 626. Further, alternatively, noorifice plates are used and coolant flow through each of channels 616and 626 is predetermined substantially as a function of sizing,configuration, shaping, and orientation of channels 616 and 626.

FIG. 12 is a front view of an alternative tip portion 700 of injectiondevice 300 that may be used with injector feed assembly 319. Tip portion700 is similar to tip portion 312 (shown in FIGS. 2, 3, 4, 6, 7, 9, and10) with the exception that tip portion 700 is transpiration-cooled witha fluid bleed system 702, wherein system 702 is an open cooling-typesystem. Also, tip portion 700 differs from tip portion 312 in thatcooling fluid outlet manifold 327 (shown in FIGS. 3, 6, and 10) forclosed cooling is not required and may be eliminated. Alternatively,manifold 327 may be used as a redundant and/or parallel coolant supplymanifold similar to cooling fluid inlet manifold 326 (shown in FIGS. 3,6, and 10). Tip portion 700 includes an alternative modular tip 704 thatis coupled to bayonet adapter portion 332 (shown in FIGS. 4, 6, 7, 9,and 10) as described above for tip portion 312 and modular tip 334(shown in FIGS. 4, 6, 7, 9, and 10). Tip portion 700 includes an innerannular portion 706 that is aligned substantially perpendicularly to,and centered about, injection device axial centerline 316. Tip portion700 also includes an outer annular portion 708. A plurality of annularinjectors 710 that include inner GOX nozzles 348, slurry nozzles 350,and outer GOX nozzles 352 (all shown in FIGS. 6, 10, and 11) are definedbetween inner annular portion 706 and outer annular portion 708. In thisalternative exemplary embodiment, portions 706 and 708 are unitarilyformed together using any methods that enable operation of modular tip704 as described herein including, without limitation, casting, forging,brazing, and welding.

Also, in this alternative exemplary embodiment, tip portion 700facilitates removing heat from outer and inner annular portions 706 and708, respectively. That is, portions of tip portion 700 including,without limitation, inner annular portion 706 and outer annular portion708 are at least partially manufactured from a porous material 712 thatfacilitates a low flow rate of fluids that are either liquid or gaseous.For example, without limitation, those portions of tip portion 700 indirect thermal contact with high temperatures and chemical species ingasification cavity 302 (shown in FIG. 2) are made of porous metallic orrefractory materials such as, without limitation, porous plates orshapes formed by sintering metallic wire and/or powdered super alloysthat are joined to the non-porous portions of tip portion 700 by one ormore methods that include, without exception, welding, brazing and otherappropriate bonding techniques. Alternatively, retention hardware (notshown) is used. In this alternative embodiment, coolant flow rates arepredetermined to facilitate prevention of undesirable quenching ofrecirculation zones 320 and 322 (both shown in FIG. 2). Furthermore,such portions also may incorporate features that enhance the efficiencyof transpiration cooling, including without limitation, features thatfacilitate impingement cooling of the inside and outside surfaces to becooled using the transpiration coolant.

During operation, cooling fluid is channeled to and/or within tipportion 700, and particularly to modular tip 704 and fluid bleed system702 in a manner similar to that described above for tip portion 312 andmodular tip 334. Therefore, in this alternative exemplary embodiment,fluid bleed system 702 facilitates heat removal from modular tip 704 viachanneling cooling fluid therein to absorb at least some of the heatgenerated within modular tip 704 and channeling such heat intogasification cavity 302 via a transpiration cooling process throughporous material 712. In this alternative embodiment, fluid bleed system702 coolant flow rates are predetermined to facilitate prevention ofundesirable quenching of recirculation zones 320 and 322 (shown in FIG.2). Fluid bleed system 702 may be operated in conjunction with a closedcooling system as described above for tip portion 312.

FIG. 13 is a flow chart of an exemplary method 800 of assemblinginjection device 300 (shown in FIGS. 2, 3, and 12). In the exemplaryembodiment, injection device 300 is extended 802 at least partially intogasification cavity 302 (shown in FIG. 2). Injection device 300 includesa plurality of substantially concentric conduits, that is, bayonetsections 321/323/324 (all shown in FIG. 3) and/or adapters 336/338/340(all shown in FIGS. 4, 6, and 10), coupled to modular tip 334 (shown inFIGS. 4, 6, 7, 9, and 10), and a plurality of cooling channels602/604/614/616/626 (all shown in FIG. 10) defined therein. Also, in theexemplary embodiment, at least one coolant distribution device, such as,without limitation, coolant manifolds 326 and 327, coolant spokes 492and 494, orifice plates 618 and 628, wall 634 (all shown in FIG. 10) andcooling fluid coils 328 (shown in FIGS. 3 and 9) and orifices 640 and642, and wall 644 (all shown in FIG. 11), is coupled 804 in flowcommunication with plurality of cooling channels 602/604/614/616/626 tofacilitate removing heat from an outer surface 354/356 (both shown inFIGS. 7 and 9) and 500/502/606/608 (all shown in FIG. 10) of injectiondevice 300.

Embodiments provided herein facilitate assembly and heat removal frominjection devices. Such injection devices may include a modular tipdevice. Using the injection devices as described herein facilitates useof such injection devices in high-temperature environments for anextended period of time without routine corrective maintenancedisassembly, reassembly, and/or replacement of the injection devices,thereby reducing operational and maintenance costs associated withnon-cooled injection devices.

Described herein are exemplary embodiments of heat removal apparatusthat facilitate heat removal from modular tip injector devices andmethods of assembling the same. Specifically, defining cooling fluidchannels and positioning fluid distribution devices within a modular tipto channel cooling fluid flows to those surface regions of the modulartip most likely to be subjected to elevated temperatures facilitatesheat removal from those surface regions. Therefore, a broader range ofmaterials that may otherwise be susceptible to a decreased life cyclemay be used. Moreover, using such modular tip heat removal apparatusfacilitates reducing operating costs associated with retrofits,preventative maintenance, corrective maintenance, as well as inspectionsof, and replacement of, the modular tips of the injection devices.

The methods and systems described herein are not limited to the specificembodiments described herein. For example, components of each systemand/or steps of each method may be used and/or practiced independentlyand separately from other components and/or steps described herein. Inaddition, each component and/or step may also be used and/or practicedwith other assembly packages and methods.

While the invention has been described in terms of various specificembodiments, those skilled in the art will recognize that the inventioncan be practiced with modification within the spirit and scope of theclaims.

1-20. (canceled)
 21. A method for assembling an injection device for usein a reactor injector feed assembly, said method comprising: coupling atleast two annular reactant conduits defined within an injector body influid communication with at least two corresponding annular reactantnozzles defined within a tip oriented on an end of the injector body;coupling a cooling fluid supply plenum to the injector body; coupling acooling fluid return plenum to the injector body; and coupling at leasttwo cooling channels in fluid communication with the cooling fluidsupply plenum and the cooling fluid return plenum, wherein at least afirst of the cooling channels is oriented radially outwardly of at leastone annular reactant nozzle and at least a second of the coolingchannels is oriented radially inwardly of the at least one annularreactant nozzle.
 22. The method in accordance with claim 21, whereinorienting a tip on an end of the injector body comprises releasablycoupling a modular tip to the injector body.
 23. The method inaccordance with claim 22, wherein releasably coupling a modular tip tothe injector body comprises configuring a center body within the modulartip, wherein the center body includes a radially outer surface that atleast partially defines the at least one annular reactant nozzle. 24.The method in accordance with claim 23, wherein said method comprisesdefining the second cooling channel in the center body.
 25. The methodin accordance with claim 21, wherein said method comprises defining thefirst and second cooling channels in the tip.
 26. The method inaccordance with claim 21, wherein said method comprises defining thefirst cooling channel in the injector body.
 27. A gasification facilitycomprising: at least one carbonaceous reactant source; at least oneoxygenated fluid reactant source; at least one gasification reactorcomprising at least one injection device coupled in flow communicationwith said at least one carbonaceous reactant source and said at leastone oxygenated fluid reactant source, said at least one injection devicecomprising: an injector body having at least two annular reactantconduits defined therein; a tip oriented on an end of said injector bodyand having at least two annular reactant nozzles defined therein,wherein said each of said least two annular reactant nozzles is coupledin fluid communication with a respective one of said at least twoannular reactant conduits; a cooling fluid supply plenum coupled to saidinjector body; a cooling fluid return plenum coupled to said injectorbody; and at least two cooling channels coupled in fluid communicationwith said cooling fluid supply plenum and said cooling fluid returnplenum, wherein at least a first of said cooling channels is orientedradially outwardly of at least one annular reactant nozzle and at leasta second of said cooling channels is oriented radially inwardly of saidat least one annular reactant nozzle.
 28. A gasification facility inaccordance with claim 27, wherein said tip comprises a modular tip thatis releasably coupled to said injector body.
 29. A gasification facilityin accordance with claim 28, wherein said modular tip comprises a centerbody that includes a radially outer surface that at least partiallydefines said at least one annular reactant nozzle.
 30. A gasificationfacility in accordance with claim 29, wherein said second coolingchannel is defined in said center body.
 31. An injection device for usein a reactor injector feed assembly comprising: an injector body havingat least two annular reactant conduits defined therein; a tip orientedon an end of said injector body and having at least two annular reactantnozzles defined therein, wherein each of said at least two annularreactant nozzles is coupled in fluid communication with a respective oneof said at least two annular reactant conduits; a cooling fluid supplyplenum coupled to said injector body; a cooling fluid return plenumcoupled to said injector body; and at least two cooling channels coupledin fluid communication with said cooling fluid supply plenum and saidcooling fluid return plenum, wherein at least a first of said coolingchannels is oriented radially outwardly of at least one annular reactantnozzle and at least a second of said cooling channels is orientedradially inwardly of said at least one annular reactant nozzle.
 32. Theinjection device in accordance with claim 31, wherein said tip comprisesa modular tip that is releasably coupled to said injector body.
 33. Theinjection device in accordance with claim 32, wherein said modular tipcomprises a center body that includes a radially outer surface that atleast partially defines said at least one annular reactant nozzle. 34.The injection device in accordance with claim 33, wherein said secondcooling channel is defined in said center body.
 35. The injection devicein accordance with claim 31, wherein said first and second coolingchannels are defined in said tip.
 36. The injection device in accordancewith claim 31, wherein said first cooling channel is defined in saidinjector body.
 37. The injection device in accordance with claim 31,wherein said injection device comprises at least one radially extendingcooling passage coupled to said first and second cooling channels. 38.The injection device in accordance with claim 31, wherein said injectorbody includes an outer wall, and said first cooling channel is definedwithin said injector body outer wall.
 39. The injection device inaccordance with claim 31, wherein said tip includes an outer wall, andsaid first cooling channel is defined within said tip outer wall. 40.The injection device in accordance with claim 31, further comprising atleast one orifice plate coupled to at least one of said first and secondcooling channels.